DESIGN AND ANALYSIS OF TWO PLATE MOLD INSERT FOR DOG BONE SPECIMEN MOHD ALIFF BIN MOHD RADZI Thesis submitted in fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Manufacturing Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG NOVEMBER 2009
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The Author grateful and would like to express sincere gratitude to supervisor
who is En. Asnul Hadi Bin Ahmad for his germinal ideas, invaluable guidance,continuous encouragement and constant support in making this research possible. He has
always impressed me with his outstanding professional conduct, his strong conviction
for science, and his belief that a Degree of Bachelor program is only a start of a life-long
learning experience. The Author appreciates his consistent support from the first day
The Author applied to graduate program to these concluding moments. The Author is
truly grateful for his progressive vision about my training in science, his tolerance of my
naïve mistakes, and his commitment to my future career. The Author also sincerely
thanks for the time spent proofreading and correcting all the mistakes.
Sincerely thanks go to all colleges and members of the staff of the Faculty
Mechanical Engineering, UMP, who helped in many ways and made The Author stay atUMP pleasant and unforgettable. Many special thanks go to member molding research
group for their excellent co-operation, inspirations and supports during this study.
The Author acknowledges sincere indebtedness and gratitude to The Author
parents for their love, dream and sacrifice throughout their life. The Author also feel
grateful to Pok Tar where helps and allows The Author done this study property with
help and prays to make this work possible with blessing of Allah S.W.T. The Author
cannot find the appropriate words that could properly describe the appreciation for their
devotion, support and faith in ability to attain the goals. Special thanks should be given
to final year students members. The Author would like to acknowledge their comments
and suggestions, which was crucial for the successful completion of this study.
This thesis deals with durability assessment for design and analysis of two plate mold
insert for dog bone specimen using selected sample. The objective of this thesis is to
design two plate mold insert and analyze the material flow of the selected product. The
thesis describes the material flow analysis to analyzed the material flow in the part and
identify the best gate locations of the components. Acrylonitrile butadiene styrene
(ABS) materials were studied in this thesis as sample of material and it is commonly
used in industry and lab. The structural three-dimensional solid modelling of two plate
mold was developed using the computer-aided drawing software. The strategy of
analysis model was developed. The material flow and gate location analysis was then
performed using Moldflow Plastic Insight software. The analysis model of the
components was analyzed using the two cavities with cold runner design. Finally, the
orientation skin for 21 number of different gate location is analyzed. From the results, itis observed that the analysis using Moldflow material flow analysis show the different
orientation skin for different gate locations. The gate locations is constrain at the
middle of the part where the area that would be test for the specimen. The orientation
skin at the both sides of the part is same but only change the length of runner. The
increase of length of runner will increase the projected area, the clamping force, filling
time and the material waste. So that, the best locations of gate is at the nearest or as
short as it can for runner length to be design. But, the first priority is the orientation
skin for the material flow. The orientation skin should be same at the middle of part
which is parallel to the strength that would be applied on testing. The final design was
done in solid modelling and details drawing using SolidWorks software. The results can
also significantly reduce the cost and time to fabricate the insert. That is also can be areference for the future works of fabrications.
Tesis ini membincangkan dengan taksiran ketahanan untuk rekaan dan analisis dua plat
acuan dengan bentuk mengikut specimen tulang anjing menggunakan saiz yang terpilih.
Objektif tesis ini ialah untuk mereka bentuk dua plat acuan dan analisa aliran bahan
bagi produk yang ditetapkan. Tesis ini menggambarkan analisis aliran bahan yang
dianalisis aliran masuk ke bahagian dan mengenal pasti pintu terbaik dimana lokasi
pada bahagian itu. Acrylonitryl butadiene styrene (ABS) bahan yang telah dipilih
untuk dianalisa dalam tesis ini sebagai sampel bahan dan ia biasanya digunakan dalam
industri dan makmal. Pemodelan dalam bentuk tiga dimensi struktur dua plat acuan
dilakukan menggunakan lukisan dan gambaran menggunakan komputer perisian.
Strategi model analisis ini telah dibangunkan. Aliran bahan dan analisis lokasi pintu
adalah dilakukan menggunakan perisian Moldflow Plastic Insight. Model analisis
bahagian-bahagian itu dianalisis menggunakan dua buah lubang berbentuk specimentlang anjing yang menggunakan reka bentuk pelari sejuk. Akhirnya, kulit orientasi
untuk 21 lokasi pintu yang berbeza dianalisa. Daripada keputusan-keputusan itu, ia
diperhatikan yang analisis yang menggunakan aliran bahan Moldflow analisa
menunjukkan orientasi berbeza kulit untuk lokasi-lokasi pintu yang berbeza. Lokasi-
lokasi pintu dielakkan di bahagian tengah di mana kawasan yang akan digunakan untuk
meguji specimen tersebut. Kulit orientasi pada kedua-dua bahagian adalah sama tetapi
hanya perbezaan dan penambahan panjang pelari yang digunakan. Peningkatan panjang
pelari akan meningkatkan luas terunjur, daya mencengkam, masa memenuh dan sisa
bahan. Untuk lokasi terbaik pintu itu adalah pada jarak terdekat atau sependek ia boleh
untuk panjang pelari direka bentuk. Tetapi, keutamaan pertama adalah pada bentuk
kulit orientasi untuk aliran bahan didalam produk. Kulit orientasi sepatutnya sama di pertengahan bahagian yang mana selari dengan arah untuk daya kekuatan yang akan
dikenakan di dalam ujian spesimen. Tujuan terakhir adalah dengan pemodelan pejal
dan lukisan lengkap menggunakan perisian SolidWorks. Keputusan-keputusan itu boleh
juga nyata sekali mengurangkan kos dan masa untuk mereka sisipan. Iaitu juga boleh
jadi suatu rujukan untuk kerja-kerja masa depan pemesinan sebenar.
Plastic injection molding is one of the most important polymer processing
operations in the plastic industry today. The plastic industry that is injection molding
process and involving manufacturing has high growth potential. Most of the products
are made from plastic material. The aim of this project is to design and analysis of two
plate mold insert for Dog Bone tensile test specimen. This work is concerned with the
design, analysis, and simulation two plate molds insert for plastic injection molding.
In designing mold insert for injection molding, the accuracy in making mold is
very important in order to reduce the cost also to prevent mold easily broken.
Previously, the engineer or designer of mold used manual analysis to the mold. But,
nowadays the technology becomes more advances and the analysis replaced by software
that can simulate the mold that want to fabricate.
The insert for two plate mold will design with two cavities of Dog Bone tensiletest specimen. The designs are completely investigate on number of cavity, number of
gate, runner system, and gate mechanism for dog bone tensile test specimen insert. The
design is focus on the application of product that has some limitation when propose the
design.
This project concern with two software which is Computer Aided Design (CAD)
and Computer Aided Engineering (CAE) Moldflow Plastic Insight (MPI) . The design
two plate mold insert start with draw the dog bone specimen which is follow the
Next, this study used the specify CAE software for analysis the material flow
which is Moldflow Plastic Insight (MPI). MPI with 5.0 versions used to determine the
best gate location for the dog bone specimen. This software will show how the material
flows into the parts in order to determine the best location for the design.
This study was focus on design the best gate location for twin cavities of dog
bone specimen insert. This design is to reduce the possibility defects that can occur and
to have the effective design with less of product defect after mold insert fabrication. All
the design was focused for two plate mold as the title of this study.
Lastly, the analysis was performed by using selected engineering material which
is Acrylonitrile Butadiene Styrene (ABS). This material selected for one sample of
material for analysis and that is suitable for many applications for engineering works.
1.5 PROJECT PLAN
Gant chart for the project plan can be referring to appendix A1 for Gant Chart PSM I
and appendix A2 for Gant Chart PSM II.
This “Projek Sarjana Muda” (PSM) consists of two parts which are PSM 1 and
PSM 2. That is separate for first semester with PSM 1 and continues with PSM 2 on
second semester. PSM1: At beginning with receives the title of project from supervisor
and supervisor gives briefly explanations about that PSM title given. Supervisor give
briefly guide to make the schedule or task planning for the whole works for PSM.
Schedule management is needed for this project to make sure the project running in progress. Then, discussion with supervisor start focused on the project title about the
objective, problem statement, and scope of project. Next, the project progress continue
by start finding the information data and all related information to the project title by
reverse engineering study and literature review from web sites, journal, reference books,
supervisor and other relevant academic material that related to this project. To get the
clear view and very understand about the project, it is require studying more on material
that related to the project topic and spend more than two week to make a literature
review. The process of literature review in continuously move from one thing to another
things. This is continuously until the project arrived to chapter 4 which is result of the
project. Every week and continuously, improvement of knowledge is needed to make
sure this project will be performing very well.
Continuing the progress, all the literature review related need to collect and get
focused to reduce the scopes of works. The literature review requires the information
and material about injection mold, mold components, injection mold design, mold
based, gating system, runner system, and the software that is required for this project.
The progresses continue with product or parts selection as a sample of product study for
this project. The sample of product which is Dog Bone tensile test specimen was
choosing. This product, scopes to standard dimension and shape follow the American
Society Test Method (ASTM) standard. Next, based on the size of selected product, the
suitable mold based size is determined which is available on our lab. The selected and
most suitable mold based is selected and do the dimensioning details with all
components These task will performed with suitable tools and equipments which are
ruler (mm), venire caliper and measuring tape (mm). All this dimensions is used as
references to redraw in CAD software to do the modeling and analysis by CAE
Moldflow Software. Next, drawing of selected sample of product and mold based as a
modeling and for analysis and design details. All these drawing were draw by CAD
software which is SolidWorks. This drawing is details with dimension as actual size as
an original product. The dimension was following the current parts and also gets the
reference of dog bone by ASTM standard. Next, the process continues with the material
selection as sample of product material to analyze the material flow. This material is
scopes to engineering plastic material which is using Acrylonitrilebutadiencestryene
(ABS) material. All the information and data collection and parameter require for this project progress will recorded as a reference for the analysis task on PSM 2. After that,
task is preparation of progress presentation and report writing chapter one, chapter two
and chapter three as a complete task for PSM 1. These tasks take two week to be finish.
In the presentation, the information and flow of project was explains to the panels. That
is details with project objective and scope that focus in. On that particular week,
preparations also include the slide presentation for the PSM 1 work progress
scrap in this type of injection mold. They are then ground into small pieces or pellets
and mixed with the virgin plastic for reuse. Cold runner injection molds are more
economical to build than hot runner molds, however they can be less economical to run
if the amount of plastic in the sprue and runner exceeds 35% of the plastic that is
injected into the part cavities (L.Sors and I.Balazs. 1989).
2.2.2 Two and Three-Plate Molds
Mold for plastic injection molding can be categorized into two main categories
that are two plate mold and three plate mold. Each type has a different design, function
and structure. The selection types of mold depend on types of product, function and
production capacity. The cost of mold fabrication also depends on the types of mold.
This study will discuss details on two-plate molds.
2.2.2.1 Two-Plate Molds
This kind of mold is used for parts that are typically gated on or around their
edge, with the runner in the same mold plate as the cavity. Two-plate mold can divided
into 3 category that is cold runner, hot runner and conventional. Figure 2.1 shows the
two-plate mold which are separated by one line called parting line into two side, core
side and cavity side. Core side content ejector pin, core insert which is moving after
plastic inject into the mold and the ejection bar will push the ejector pin and the ejector
pin then push the part out from the mold. Cavity side is a fixed side, not moving and
content feed system (sprue, runner and gate). Plastic material will injected from the
machine nozzle into a sprue bush and through the runner to the cavity. Moldtemperature controlled by temperature controller. That have 5 medium usually used to
control the mold temperature that is chiller (3°C to 35°C), normal water (35°C to 45°C),
hot water (45°C to 90°C), hot oil (90°C to 250°C) and ethylene glycol (90°C to 250°C)